Method of ultrasonic drawing of sheet metal



May 9, 1967 L. (moss METHOD OF ULTRASONIC DRAWING 0F SHEET METAL Filed March 29, 1965 INVENTOR- [0 feoss BY 4Z7QAKX3 d4 7/24 saw/c 10509702 United States Patent 3,318,129 METHOD OF ULTRASONIC DRAWING 0F SHEET METAL Leo Gross, 3611 217th St., Bayside, N.Y. 11361 Filed Mar. 29, 1965, Ser. No. 443,418 Claims. (Cl. 72-199) The present invention relates to rolling metal and more particularly to a method and apparatus for the ultra sonically drawing of sheet metals.

In conventional metal rolling the sheet of metal being rolled is deformed by direct contact pressure on the sheet of metal as it passes between the rollers under compression while being pulled under tension. This process is generally known as contact-pressure rolling.

The rolling process is employed to reduce the thickness of the material being rolled by passing the material between a pair of rollers which are under compression.

When using conventional rolling methods to substantially reduce the thickness of the material being rolled, it has been necessary to repeatedly pass the material being so reduced in thickness through the roll press. Further, between the repeated passes through the roll press, it is often necessary to anneal the material being rolled so as to eliminate the effects of repeated working and to reduce the internal stress upon the material. Such intermediate annealing steps are both time consuming and costly and with certain types of materials are not possible or practical due to the fusing and hardening properties of the various elements which comprise the material which are not readily subject to repeated annealing.

When using certain metals or metal alloys such as steel sheet or billets and the like, it becomes necessary to roll the sheet sheet or billets several times to obtain a desired thickness when reducing the initial bulk of the steel material to a drawn sheet. In the past, using the compression rolling methods, heretofore available, it has been necessary to anneal the steel during each successive step of rolling so as to produce a sheet of the desired thickness without the internal metal stress and flaws which develop during repeated rollings.

By applying ultrasonic vibration during the rolling process an improved result is obtained whereby the material being rolled is reduced in thickness much more in each pass through the rollers than has heretofore been possible, While the necessity for annealing is reduced or eliminated entirely, thus resulting in increased efficiency and greatly reducing the need for multiple rolling and intermediate annealing.

Accordingly, it is an object of the present invention to provide a method for the ultrasonic drawing of sheet metals.

A further object of the invention is to provide a method for the ultrasonic drawing of sheet metals whereby metals can be rolled and drawn to a desired thickness utilizing fewer passes of the metal through the rollers to obtain desired thickness.

Further, it is an object of the present invention to provide a method for'ultrasonically drawing sheet metals which will produce a metal sheet having a smooth outer surface which is free from internal stresses caused by repeated steps of rolling and annealing.

Further, it is an object of the present invention to provide a method for ultrasonically drawing metals which will reduce the number of rolling steps necessary to deform the metal to the desired thickness, thereby reducing labor costs and the ultimate cost of the metals to the user or consumer.

These, together with the various ancillary objects and features oft-he invention, which will become apparent as the following description proceeds, are obtained by this 3,318,129 Patented. May 9, 1967 method, illustrative embodiments and steps being shown in the accompanying drawings, by way of example only, wherein:

FIG. 1 is diagrammatic view in elevation showing schematically the apparatus for ultrasonically drawing sheet metals;

FIG. 2 is a perspective view diagrammatically showing the ultrasonic rolling mill which may be employed for ultrasonically drawing and rolling sheet metals and particularly showing an ultrasonic vibrator connected thereto; and,

FIG. 3 is a perspective view of a preferred arrangement of an ultrasonic vibrating device for use in the ultrasonic drawing and rolling of sheet metals.

Although various structures are illustrated in the accompanying drawings, it is to be noted that the preferred apparatus is illustrated in FIG. 3.

Referring now to the drawings and in particular to FIG. 1, there is diagrammaticaly illustrated a sheet metal rolling and drawing apparatus generally indicated at 10 which employs an ultrasonic vibratory device. The sheet metal rolling and drawing mill has a bed 12 over which the material to be deformed and reduced in thickness passes. For the purpose of illustration, however, not limited specifically thereto, a four-high type rolling mill is illus trated having a narrow diameter roller 14 located directly above the bed which narrow diameter roller 14 is adapted to contact the sheet of material being worked and roll the same. Located directly below the bed 12 and extending upwardly to the same height as the uppermost portion of the bed through a cutout, therein is a narrow diameter roller 16, which is rotatably mounted in such a manner as to prevent vertical or horizontal travel of the roller 16. Located directly below the narrow diameter roller 16 is a second wide diameter roller 18 which may be of the same or greater diameter than roller 16 and upon which roller 16 rests. Roller 18 is rotatably mounted so as to prevent any vertical or horizontal movement. The roller 16 is provided with an outwardly extending axle or hub 20 which extends outwardly from the side wall of the roller and is adapted to be secured in a bearing or support on a brace which is not shown. Likewise, roller 18 is provided with an axle or hub 22 which extends outwardly from the side wall of the roller 18 and is also connected to a brace or table not shown. The rollers 16 and 18 abut each other and are rotatable against each other. Located directly above roller 14 is a larger diameter roller 24 which roller lies against roller 14 and applies pressure uniformly over the width of the roller 14. The roller 14 is provided with an axle or hub 26 which extends outwardly from the side edges thereof for securement purposes as will be set forth in detail as the specification continues. Likewise, roller 24 is provided with an axle or hub 28 which extends outwardly beyond the side edges of the roller.

A vertical U-shaped clamping brace 31 extends outwardly beyond the side edges of rollers 14, 24 and has axle or hu-b receiving apertures or bearings formed therein for the purpose of maintaining rollers 14 and 24 in vertical rotatable alignment with each other. The two depending legs of the vertical brace 30 are of identical configuration and connecting the two legs of the U- shaped brace is a central section 32 to which there is connected a force applying member 34 such as a hydraulic or mechanically driven force press for the purpose of increasing the downward force which is applied to the rollers 14 and 24.

Suitably mounted above the bed 12 so as to permit the material to be rolled to pass thereunder is an ultrasonic vibrator 36. Extending outwardly from the ultrasonic vibrator 36 and connected thereto is a two-armed member 38 having a pair of horizontal extending arms 46 extending outwardly therefrom, which arms are spaced apart from each other and extend forwardly so as to overlie and connect with the vertical brace and the outwardly extending axle or hub 26 of roller 14. The horizontally extending arms 49 are provided with apertures or bearings 42 which are slipped over the axle or hub 26 and serve to position the horizontal arms thereon.

The material which is to be rolled is placed upon the bed 12, and it is advanced toward and between rollers 14, 16 and once in position therebetween downward force is applied by vertical clamping brace 30 causing material to be deformed by the contact force applied by the rollers 14 and 16 to a desired thickness as a result of the force which is applied to the material by the rollers 14, 16. As the material 50 is passing between rollers 14 and 16, the ultrasonic vibrator 36 is vibrating and thereby transmitting the ultrasonic vibration through the two armed member 38 to the roller 14 in turn causing roller '14 to be ultrasonically vibrated in a back and forth manner as the material passes between rollers 14 and 16. In sheet material rolling and drawing, it has been found that a sharp angle of attack for the application of pressure by the roller is essential in order to most effectively roll and deform the sheet material. For this reason the small diameter rollers 14 and 1d are used to contact the material 50 which is being rolled. If larger diameter rollers were to be used in place of the smaller diameter rollers 14 and 16, the pressure applied by the rollers to the material would be distributed over a much larger surface of the material as it was being rolled and would therefore reduce the efficiency of the rolling process and require additional passes through the roller.

Where it is desired to deform the metal and reduce the thickness thereof in a greater degree than can effectively be accomplished during a single rolling utilizing the ultrasonic vibration process, it is possible to employ a plurality of four high rollers one right after another each one having a successively greater pressure applied thereto so as to deform the material in a series of steps without the need for intermediate annealing of the material. In view of the fact that the ultrasonic vibration greatly improves the efliciency of the rolling process, it is possible to have a sheet of material pass through a plurality of rolling mills in rapid succession as have not been possible in the past thereby greatly speeding up the rolling process and eliminating the need for intermediate annealing.

Further, by applying the ultrasonic vibrations to the roller 14 and imparting said vibration to the material 50 as the same passes between rollers 14 and 16, the molecular structure of the material is vibrated thereby reducing internal cohesive stress between the molecular structure reducing internal stress and eliminates steps of annealing heretofore necessary.

When the material 50 is inserted at the left of the bed 12 as is digrammatically shown in FIG. 1, the roller 14 will rotate in a counterclockwise direction, thereby causing roller 24, which rests upon roller 14, to rotate in a clockwise direction. Likewise, roller 16 will rotate in a clockwise direction, causing roller 18 to rotate in a counterclockwise direction during the rolling process.

Referring now specifically to FIG. 3, there is seen the preferred arrangement for imparting ultrasonic vibration during the rolling process by means of side to side vibration means disposed perpendicularly to the path of travel of the material being rolled. The rolling mill is generally designated at and the ultrasonic vibrator 6 2 is secured to the rolling mill 60 or to a separate support structure by suitable securement means (not shown), at a location outwardly of the side edge of the rollers 14, 16, 18, 24. EX- tending outwardly from and connected to the ultrasonic vibrator 62 is a coupling linkage 64 which terminates on axle 26 or is integrally formed as a part thereof. The direct coupling of the ultrasonic vibrator to the roller has been formed to be more effective in that the vibra- 4 tion imparted to the roller may be more accurately con trolled.

As the material to be rolled passes between rollers 14 and 16, ultrasonic vibration is imparted to the roller 14 at a right angle to the direction of the material being rolled thereby assisting in the deformation of the material by applying ultrasonic vibratory energy perpendicular both to the direction of the downward pressing force and to the direction in which the material is being drawn, while aligning the molecules of the material being rolled rendering the material more malleable and homogeneous.

It has been discovered that the ultrasonic vibration may be above 20 kilocycles per second with an upper vibration limit being in the order of 500 kilocycles per second. It is further noted that the optimum frequency of ultrasonic vibration can be selected with relation to the particular material being rolled and the thickness of the material, thereby affording a maximum efficiency in the rolling process.

A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

'1 claim:

1. A method of rolling metal comprising the steps of passing metal of a discrete thickness between rollers while simultaneously applying force to at least one of said rollers to compress said metal, and applying ultrasonic vibration to said metal while passing said metal between said rollers to reduce the thickness of said metal.

2. A method of rolling metal according to claim 1 wherein said ultrasonic vibration is of the rate of at least 20 kilocycles per second.

3. A method of rolling metal comprising the steps of passing metal of a discrete thickness between rollers of different diameters while simultaneously applying force to at least one of said rollers to compress said metal, and applying ultrasonic vibration to one of said rollers, to transmit said ultrasonic vibration to said metal while passing said metal between said rollers to reduce the thickness of said metal, said ultrasonic Vibration being at the rate of at least 20 kilocycles per second.

4. A method of rolling metal according to claim 3 wherein said ultrasonic vibration is transmitted to one of said rollers in a direction perpendicular to the direction of the rolling.

5, A method of rolling metal comprising the steps of passing metal of a discrete thickness between a large diameter roller and a small diameter roller while simultaneously applying a compressing force to said small diameter roller to compress said metal as it passes between said small diameter and said large diameter rollers, and applying ultrasonic vibration to said small diameter roller,

to transmit said ultrasonic vibration to said metal while passing said metal between said rollers to reduce the thickness of said metal, said ultrasonic vibration being at the rate ranging between 20 kilocycles per second and 500 kilocycles per second.

6. A method of rolling metal according to claim 5, wherein said ultrasonic vibration is transmitted to said small diameter roller in a perpendicular direction to the direction of the rolling.

7. An apparatus for rolling metal comprising a bed, at least one pair of opposed rollers arranged in alignment with said bed, means for passing metal to be rolled over said bed and between said rollers, means engaging at least one of said rollers to apply compressive force on the metal to be rolled, and ultrasonic vibrator means operatively connected to at least one of said rollers for imparting ultrasonic vibrations to said rollers and to the metal to be rolled.

3. An apparatus for rolling metal comprising a bed,

at least one part of opposed rollers arranged in alignment with said bed, one of said rollers being of a large diameter, the other of said rollers being of a smaller diameter means for passing metal to be rolled over said bed and between said rollers, means engaging at least one of said rollers to apply compressive force to the metal to be rolled, and ultrasonic vibrator means operatively connected to at least one of said rollers for imparting ultrasonic vibrations to said rollers and to the metal to be rolled.

9. An apparatus for rolling metal comprising a bed, at least one pair of vertically superposed opposed rollers arranged in alignment with said bed, the lower of said rollers being of a relatively large diameter, the upper of said rollers being of a relatively smaller diameter, means for passing metal to be rolled over said bed and between said rollers, means engaging said smaller roller to apply compressible force on the metal to be rolled, and ultrasonic vibrator means operatively connected to said smaller roller for imparting ultrasonic vibrations to said roller and to the metal to be rolled.

10. An apparatus for rolling metal comprising a bed, at least one pair of relatively opposed rollers arranged in alignment with said bed, one of said rollers being of a large diameter, the other of said rollers being of a smaller diameter, means for passing metal to be rolled over said bed and between said rollers, means engaging at least one of said rollers to apply compressible force on the metal to be rolled, and ultrasonic vibrator means located outwardly of said bed and said rollers, said vibrator means being operatively connected to at least one of said rollers for imparting ultrasonic vibrations to said rollers and to the metal to be rolled in a direction perpendicular to the path of travel of the metal being rolled.

No references cited.

WILLIAM W. DYER, IR., Primary Examiner.

G. A. DOST, Assistant Examiner. 

1. A METHOD OF ROLLING METAL COMPRISING THE STEPS OF PASSING METAL OF A DISCRETE THICKNESS BETWEEN ROLLERS WHILE SIMULTANEOUSLY APPLYING FORCE TO AT LEAST ONE OF SAID ROLLERS TO COMPRESS SAID METAL, AND APPLYING ULTRASONIC VIBRATION TO SAID METAL WHILE PASSING SAID METAL BETWEEN SAID ROLLERS TO REDUCE THE THICKNESS OF SAID METAL. 